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Clean Hydrogen Partnership

Chemical reaction in a pharmaceutical company

Event

Event ID
745
Quality
Description
An employee was preparing a batch of glycol stearate emulsifier in a vessel. Upon completion of product, the quality control lab reported that the pH was too high and the product needed to be bleached.
When the employee reached the step of adding the sodium borohydride, he decided to relieve the pressure in the vessel by opening the valve used to introduce sodium chlorite. As he opened the valve, sodium chlorite (liquid) residue discharged, spraying the grating and the plastic bucket which contained sodium borohydride. The sodium borohydride reacted with the sodium chlorite, producing hydrogen gas which flashed into the employee's face. He was wearing splash goggles as face and eye protection, but nevertheless he experienced burns.
Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Fire (No additional details provided)
Macro-region
North America
Country
United States
Date
Root causes
Root CAUSE analysis
Accidentally produced hydrogen due to human error.

Facility

Application
Chemical Industry
Sub-application
Pharmaceutical production
Hydrogen supply chain stage
All components affected
Chemical reactor vessel (glycol stearate emulsifier)
Location type
Unknown
Location description
Industrial Area
Operational condition
Pre-event occurrences
The event occurred during a manually operated chemical process. It is assumed that this operation was part of the normal production cycles.

Emergency & Consequences

Number of injured persons
1
Number of fatalities
0

Event Nature

Release type
Gas-liquid mixture
Involved substances (% vol)
H2,
NaClO2,
NaBH4
Presumed ignition source
Run-away reaction
Flame type
Flash fire

References

Reference & weblink

Occupational Safety and Health Administration (OHSA) Inspection 112128152, <br />
https://www.osha.gov/pls/imis/establishment.inspection_detail?id=112128…, <br />
(accessed November 2020)

JRC assessment